Method for manufacturing a blind spot indicator for a vehicular exterior rearview mirror assembly

ABSTRACT

A method for manufacturing a blind spot indicator module for a vehicular exterior rearview mirror assembly includes providing a housing, a rear cover and a circuit board. The circuit board is disposed at the housing and the rear cover is attached to a rear end of the housing to encase the circuit board, whereby electrical terminals extending from the circuit board are disposed between a first connector portion of the housing and a second connector portion of the rear cover, thereby forming an electrical connector configured for connection to another electrical connector for electrically connecting circuitry of the circuit board at least to electrical power when the blind spot indicator module is used by an exterior rearview mirror assembly that is attached to a vehicle. The circuitry includes a light emitting diode that emits light when electrically powered, and a diffuser element diffuses light emitted by the light emitting diode.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 15/361,745, filed Nov. 28, 2016, now U.S. Pat. No. 9,713,986,which is a continuation of U.S. patent application Ser. No. 15/149,336,filed May 9, 2016, now U.S. Pat. No. 9,505,350, which is a continuationof U.S. patent application Ser. No. 14/886,287, filed Oct. 19, 2015, nowU.S. Pat. No. 9,333,909, which is a continuation of U.S. patentapplication Ser. No. 14/690,746, filed Apr. 20, 2015, now U.S. Pat. No.9,162,624, which is a continuation of U.S. patent application Ser. No.14/330,677, filed Jul. 14, 2014, now U.S. Pat. No. 9,013,288, which is acontinuation of U.S. patent application Ser. No. 14/015,441, filed Aug.30, 2013, now U.S. Pat. No. 8,779,937, which is a continuation of U.S.patent application Ser. No. 13/660,313, filed Oct. 25, 2012, now U.S.Pat. No. 8,525,697, which is a continuation of U.S. patent applicationSer. No. 13/353,490, filed Jan. 19, 2012, now U.S. Pat. No. 8,305,235,which is a continuation of U.S. patent application Ser. No. 13/107,307,filed May 13, 2011, now U.S. Pat. No. 8,102,279, which is a continuationof U.S. patent application Ser. No. 12/264,669, filed Nov. 4, 2008, nowU.S. Pat. No. 7,944,371, which claims benefit of U.S. provisionalapplications, Ser. No. 61/019,478, filed Jan. 7, 2008, and Ser. No.60/985,446, filed Nov. 5, 2007, which are hereby incorporated herein byreference in their entireties. U.S. patent application Ser. No.13/660,313 is also a continuation-in-part of U.S. patent applicationSer. No. 13/572,045, filed Aug. 10, 2012, now U.S. Pat. No. 8,466,779,which is a continuation of U.S. patent application Ser. No. 13/290,644,filed Nov. 7, 2011, now U.S. Pat. No. 8,242,896, which is a continuationof U.S. patent application Ser. No. 12/446,507, filed Apr. 21, 2009, nowU.S. Pat. No. 8,058,977, which is a 371 national phase application ofPCT Application No. PCT/US07/82099, filed Oct. 22, 2007, which claimsbenefit of U.S. provisional applications, Ser. No. 60/970,687, filedSep. 7, 2007; Ser. No. 60/918,089, filed Mar. 15, 2007; and 60/853,850,filed Oct. 24, 2006.

FIELD OF THE INVENTION

The present invention relates to exterior rearview mirror assembliesand, more particularly, to an exterior rearview mirror assembly having ablind spot/object detection indicator and/or a lane change aid (LCA)indicator and/or a turn signal or other indicator at the exteriorrearview mirror assembly.

BACKGROUND OF THE INVENTION

It is known to provide an object in a blind spot detection/LCA systemfor a vehicle that detects the presence of another vehicle or object inthe lane next to the host vehicle, where it may be difficult for thedriver of the host vehicle to determine whether or not there is anothervehicle or object adjacent to the host vehicle. Such an object in ablind spot detection/LCA system often includes a visual indicator thatvisually indicates the detection of another vehicle or object to thedriver of the host vehicle. It is also know to provide a turn signalindicator that is activated when a turn signal is activated by thedriver of the host vehicle so as to provide an indication of the vehicleturning or changing lanes to the driver of a vehicle in an adjacent laneto the host or subject vehicle or to another person external to the hostor subject vehicle. The visual indicator or indicators (commonly a lightemitting diode or the like) of such systems is/are often located at themirror reflective element of the exterior rearview mirror assembly.

The object/LCA visual indicator or indicators indicate or alert thedriver of the host vehicle of the presence or impending presence ofanother vehicle or object in a blind spot in an adjacent side lane thattypically cannot be readily seen within the field of view of theexterior mirror reflective element of the exterior mirror assemblymounted at that side of the vehicle and/or cannot be readily seen by thedriver's peripheral vision or the like. The object/LCA visual indicatorstypically are arranged to be viewable principally or solely by thedriver of the host vehicle and not by drivers of other vehicles.Similarly, the turn signal visual indicator or indicators indicate oralert a person external of the host vehicle (such as the driver ofanother vehicle alongside or approaching the host vehicle) that the turnsignal of the host vehicle is activated to indicate that the driver ofthe host vehicle is contemplating or commencing a turn or lane change orthe like. It is desirable that such turn signal visual indicators arenot readily viewable by the driver of the host vehicle when they areactivated. Because of vehicle regulations and mirror and vehicleconfigurations and geometries, and because of the need to provide anuninterrupted reflective surface to satisfy the likes of the FMVSS 111field of view regulation, blind spot/LCA indicators in the prior art aretypically located towards or at the outboard edge, and typically towardsor at the upper corner/quadrant, of the reflective mirror element of theexterior mirror assembly.

Somewhat costly and complicated indicator constructions have beencontemplated that, when placed behind and supported by the mirrorreflective element, attempt to have their projected beam of emittedlight directed principally to be viewed by the driver of the hostvehicle (or other persons external to the host vehicle for turn signalapplications) through the mirror reflective element and shielded fromview by other drivers in blind spot alert detection systems (or from thedriver of the host vehicle for turn signal applications). In someapplications, the mirror reflective element may have a transflectivereflector coating or may have a window or port formed in anon-transflective reflector coating. For example, transflective mirrorcoatings (such as, for example, those described in U.S. Pat. Nos.3,280,701; 6,855,431; 5,724,187; 5,340,503; 6,286,965; 6,196,688;6,045,023; 5,788,357; 5,535,056; 5,751,489 and 6,065,840, which arehereby incorporated herein by reference in their entireties) may beused, or alternately, a transmissive window or port may be formed in thereflective coating or coatings of the mirror reflective element (suchas, for example, those described in U.S. Pat. Nos. 6,005,724; 6,257,746;6,111,683, 5,786,772, 5,313,335 and 5,285,060, which are herebyincorporated herein by reference in their entireties). An illuminationsource or indicator may be positioned so as to direct or emitillumination through the window or display area and toward the driver ofthe host vehicle so as to be viewable by the driver of the host vehicle(or outwardly away from the vehicle so as to be generally not viewableby the driver of the host vehicle for turn signal applications).

Such a mirror assembly and indicator often include a baffle or otherlight directing element and an illumination source positioned at therear of the mirror reflective element (and generally at the transmissivewindow or port if applicable). The baffle shields from view by anobserver or the light directing element directs the light orillumination from the illumination source toward the desired orappropriate viewer (such as the driver of the host vehicle for blindspot/LCA applications or the driver of another vehicle for turn signalapplications) and away from others (such as away from other drivers forblind spot/LCA applications or away from the driver of the host vehiclefor turn signal applications).

Typically, such baffles or other light directing elements are adhered tothe rear surface of the mirror reflective element. In some applications,the illumination source may be provided as a module to the mirrorassembly facility and adhered to the rear of the mirror reflectiveelement as a unit or module (for instance, light from LEDs facing andemitting light in the direction away from the mirror element may bereflected back towards the mirror reflector, and hence through themirror element, using suitably angled or disposed mirrored surfaces).After the baffle or module is attached to the reflective element, theback plate of the mirror assembly may be adhered to the mirrorreflective element to complete the mirror reflector sub assembly that isthen assembled with the actuator and casing and other components to formthe complete mirror assembly for mounting to the side of the vehicle.

A variety of interior and exterior mirror assemblies with indicators areknown in the art, such as U.S. Pat. Nos. 5,355,284; 5,788,357;6,257,746; 6,005,724; 5,481,409; 6,111,683; 6,045,243; 6,264,353;6,512,624; 6,356,376; 2,263,382; 2,580,014; 3,266,016; 4,499,451;4,588,267; 4,630,904; 4,623,222; 4,721,364; 4,906,085; 5,313,335;5,587,699; 5,575,552; 5,436,741; 5,587,699; 5,938,320; 6,700,692 and5,786,772, and Canadian Pat. No. CA 1,063,695, and Great Britain PatentSpecification 1,172,382 and Pat. Abstracts of Japan Publication No.0917573, published Jul. 8, 1997, and PCT Publication WO 95/30495,published Nov. 16, 1995, which are all hereby incorporated herein byreference in their entireties.

Therefore, there is a need in the art for an improved object in a blindspot/LCA indicator that is readily viewable by a driver of the hostvehicle and not visible or viewable by a driver of another vehicleand/or an improved turn signal indicator that is readily viewable by thedriver of another vehicle and not visible or viewable by the driver ofthe host vehicle.

SUMMARY OF THE INVENTION

The present invention provides an object in a blind spot indicator orlane change assist (LCA) indicator or turn signal indicator or otherindicator that is integral with the mirror reflector carrier or backplate of the mirror reflector sub-assembly so as to be positioned at andattached to the mirror reflective element as the back plate is adheredor otherwise attached at the back of the mirror reflective element.Preferably, the signal indicator is provided as a sealed orsubstantially sealed unit or module that can be snapped into orotherwise attached or secured (preferably mechanically but optionallyadhesively) at the mirror back plate (and does so substantially orwholly sealingly to limit or substantially preclude water ingress to themodule so that the module and back plate are substantially waterimpervious), preferably at the mirror sub-assembly manufacturingoperation when the mirror reflective element (and any associated heateror other item or element) is joined to the mirror back plate. Theindicator assembly or indicator module of the present invention mayutilize aspects of the indicators described in U.S. Pat. Nos. 7,038,577;6,882,287; 6,198,409; 5,929,786 and 5,786,772, and/or U.S. patentapplication Ser. No. 11/520,193, filed Sep. 13, 2006, now U.S. Pat. No.7,581,859; Ser. No. 11/226,628, filed Sep. 14, 2005 and published Mar.23, 2006 as U.S. Publication No. US-2006-0061008; and/or Ser. No.11/315,675, filed Dec. 22, 2005, now U.S. Pat. No. 7,720,580, and/or PCTApplication No. PCT/US2006/026148, filed Jul. 5, 2006 and published Jan.11, 2007 as International Publication No. WO 2007/005942, and/or PCTApplication No. PCT/US2006/018567, filed May 15, 2006 and published Nov.23, 2006 as International Publication No. WO 2006/124682, and/or PCTApplication No. PCT/US07/82099, filed Oct. 23, 2007 and published May 2,2008 as International Publication No. WO 2008/051910; and/or U.S.provisional application Ser. No. 60/954,953, filed Aug. 9, 2007, whichare all hereby incorporated herein by reference in their entireties. Thepresent invention thus provides a mirror reflector carrier or back platewith an integrated blind spot indicator/indicators and/or turn signalindicator/indicators and/or other indicator/indicators.

According to an aspect of the present invention, an exterior rearviewmirror assembly for a vehicle includes a mirror reflective element, aback plate and an indicator or display device. The back plate may bemolded or formed with a receiving portion or mounting portion or pocketfor receiving or mounting an indicator assembly or module thereto. Theback plate is attached to the rear surface of the reflective element(the surface opposite the front surface, with the front surface facinggenerally rearward and toward the driver of the vehicle when the mirrorassembly is mounted to the vehicle). The indicator mounting portionextends rearward away from the reflective element and may be integrallyformed with the back plate, preferably by injection molding. Theindicator assembly or module includes a housing that houses at least oneillumination source, such as a light emitting diode, and includeselectrically conducting terminals electrically connected to theillumination source and accessible at the housing (such as at a plug orsocket portion of the housing) for electrical connection of theindicator module to an electrical lead of the mirror assembly.

The housing is preferably formed so as to be readily attached orconnected or snapped to the receiving portion or mounting portion of theback plate. When so mounted, light emitted by the light source orsources of the indicator module is transmitted through the reflectiveelement for viewing by a person viewing the reflective element at anangle that generally corresponds to the angle established by theindicator mounting portion and/or housing, while shielding or shadingthe light from viewing by a person viewing the reflective angle atanother angle that does not generally correspond to the angleestablished by the indicator mounting portion and/or housing.

The mirror back plate, including the indicator mounting portion ordisplay receiving portion, may be configured to orient the housing andindicator module at a predetermined angle so that light exiting theindicator module when the light source is activated is directed one of(a) generally away from the vehicle when the mirror assembly is mountedto the vehicle so as to be principally viewed by drivers of othervehicles and so as to be substantially not viewed by the driver of thehost vehicle, and (b) generally toward the driver of the vehicle whenthe mirror assembly is mounted to the vehicle so as to be principallyviewed by the driver of the host vehicle and so as to be substantiallynot viewed by drivers of other vehicles.

Optionally, the display or indicator element is associated with a blindspot detection system of the vehicle. Optionally, the display element isassociated with a turn signal of the vehicle. Optionally, the displayelement may comprise first and second display elements, with a firstdisplay element being associated with a turn signal of the vehicle and asecond display element being associated with a blind spot detectionsystem of the vehicle.

The back plate may comprise a plastic molding, such as a plastic moldingformed by injection molding or co-injection molding or the like. Theback plate may be formed with an attaching portion, such as a raisedannular ring or annular prongs or annular snaps or the like at its rearsurface (opposite from the mounting face or surface that attaches to themirror reflective element) for attaching the back plate to a mirroractuator (for manually or electrically adjusting an angle of the mirrorreflective element relative to the mirror casing).

Therefore, the present invention provides a display device or indicatorat the back plate of a mirror reflector sub-assembly. The mirrorreflector sub-assembly thus may achieve enhanced assembly processes, andmay be supplied or provided to a mirror manufacturer or assembler as aunit that includes the indicator mounting portion (and that may alsoinclude the indicator) and display. The integrally formed back plate andindicator mount or mounting portion may be readily attached to themirror reflective element, and the indicator assembly or module may bereadily plugged into or connected to or received in the indicator mountto assemble the mirror reflector sub-assembly. Electrical connection maybe readily made to the electrical terminals of the indicator module viaa suitable connector. The back plate may include one or more indicatormounts or mounting portions and associated light baffles for providingone or more displays at the reflective element, such as a blind spot/LCAdisplay and/or a turn signal display and/or the like.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of an exterior mirror assembly with a an indicator orindicator module in accordance with the present invention, shown asviewed in the direction of travel of the vehicle;

FIG. 2 is a plan view of an indicator module of the present invention,shown mounted at a back plate of a mirror reflective element;

FIG. 3 is a sectional view of the indicator module and back plate andreflective element, taken along the line A-A in FIG. 2;

FIG. 4 is an exploded perspective view of an indicator module and backplate of the present invention;

FIG. 5 is a sectional view of a back plate and indicator moduleconstruction in accordance with the present invention;

FIG. 6 is a sectional view of another back plate and indicator moduleconstruction of the present invention;

FIG. 7 is a sectional view of another back plate and indicator moduleconstruction of the present invention;

FIG. 7A is a schematic of the indicator module of FIG. 7, showing thereflection of light along the tube of the module;

FIG. 8 is a sectional view of another back plate and indicator moduleconstruction of the present invention;

FIG. 9 is an exploded perspective view of another indicator module andback plate of the present invention;

FIG. 10 is a plan view of the indicator module of FIG. 9, shown mountedat a back plate of a mirror reflective element;

FIG. 11 is a sectional view of the indicator module and back plate andreflective element, taken along the line XI-XI in FIG. 10;

FIGS. 12A-C are elevations of an exemplary indicator module of thepresent invention;

FIG. 13 is an exploded perspective view of another indicator module andback plate of the present invention;

FIG. 14 is a plan view of the indicator module of FIG. 13, shown mountedat a back plate of a mirror reflective element;

FIG. 15 is a sectional view of the indicator module and back plate andreflective element, taken along the line XV-XV in FIG. 14; and

FIG. 16 is an exploded perspective view of another indicator module andback plate of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depictedtherein, an exterior rearview mirror assembly 10 for a vehicle includesa mirror reflector sub-assembly 12 and a mirror shell or casing 14 (FIG.1). Mirror assembly 10 is mounted at the side of a host or subjectvehicle (not shown). As shown in FIG. 2, mirror reflector sub-assembly12 includes a mirror reflective element 18 and a mirror reflectorcarrier or back plate 20 attached to or mounted to or adhered to a rearsurface 18 a of mirror reflective element 18. Mirror assembly 10includes an indicator or display element or device or signal indicationmodule 22 that is disposed at back plate 20 and behind reflectiveelement 18, and that is operable to provide a display or indication 16at the reflective element for viewing the display or indication throughthe mirror reflective element. Signal indication module 22 includes ahousing 24 (that is received into or attached to an indicator receivingportion or mounting portion or structure 26 of back plate 20 so as to bedisposed generally at a rear surface of a planar portion 20 a of backplate 20) and an illumination source or indicator 28, such as one ormore light emitting diodes (LEDs) or other suitable illumination source.In the illustrated embodiment, the mirror assembly includes a signalindication module 22 for an object detection in a blind spot detectionsystem or LCA system (with the indicator module being angled andoperated to provide a signal that is principally viewable by the driverof the vehicle), as discussed below, but could also or otherwise includea display device for a turn signal indicator or signal indication moduleor other indicator device (as also discussed below). The indicatorelement or signal indication module thus may be readily mounted to orattached to an indicator mounting portion of the back plate 20. Thesignal indication module and reflective element sub-assembly may utilizeaspects of the indicators and reflective elements described in U.S. Pat.Nos. 7,038,577; 6,882,287; 6,198,409; 5,929,786 and 5,786,772, and/orU.S. patent application Ser. No. 11/520,193, filed Sep. 13, 2006, nowU.S. Pat. No. 7,581,859; Ser. No. 11/226,628, filed Sep. 14, 2005 andpublished Mar. 23, 2006 as U.S. Publication No. US-2006-0061008; and/orSer. No. 11/315,675, filed Dec. 22, 2005, now U.S. Pat. No. 7,720,580,and/or PCT Application No. PCT/US2006/026148, filed Jul. 5, 2006 andpublished Jan. 11, 2007 as International Publication No. WO 2007/005942,and/or PCT Application No. PCT/US2006/018567, filed May 15, 2006 andpublished Nov. 23, 2006 as International Publication No. WO 2006/124682,and/or PCT Application No. PCT/US07/82099, filed Oct. 23, 2007 andpublished May 2, 2008 as International Publication No. WO 2008/051910;and/or U.S. provisional application Ser. No. 60/954,953, filed Aug. 9,2007, which are all hereby incorporated herein by reference in theirentireties.

Optionally, the mirror assembly may include multiple display elements ordevices or signal indication modules (such as two or more displayelements or devices or signal indication modules) for providing both anobject in a blind spot/LCA indicator and display area and a turn signalindicator and display area. The two or more signal indication modulesmay be incorporated together into a single unitary display module orunit (and thus with a common connector incorporated in the singleunitary module and servicing, for example, a commonly housed turn signalindicator element and blind spot indicator element), or the two or moresignal indication modules may be separate display devices (for example,a LCA blind spot indicator unitary module may be disposed at abottom/lower inward portion of the mirror sub-assembly and a separateturn signal indicator unitary module may be disposed at an upper outwardportion of the mirror sub-assembly), while remaining within the spiritand scope of the present invention. Optionally, for example, a turnsignal indicator or device or element or module of the present inventionmay be incorporated into a mirror sub-assembly, and the exteriorrearview mirror assembly may include a blind spot or lane change assistindicating device or element at a portion of the mirror casing (such asat an inboard facing portion of the casing that faces generally inboardtoward the side of the vehicle so as to be readily viewable by thedriver of the vehicle), such as by utilizing aspects of the indicatingelements described in PCT Application No. PCT/US2006/026148, filed Jul.5, 2006 and published Jan. 11, 2007 as International Publication No. WO2007/005942, which is hereby incorporated herein by reference in itsentirety. Optionally, and desirably, the signal indication module 22 maybe purchased as a display element assembly (including a circuit elementand circuitry, which may be attached at the rear of the housing) andassembled to the mirror reflective element sub-assembly 12, such as at amirror assembly facility.

As shown in FIGS. 3 and 4, signal indication module 22 includes acircuit element 32, such as a printed circuit board or the like (such asa rigid or flexible circuit board or element), with a singleillumination source or LED 28 disposed thereat (such as surface mountedor otherwise disposed LED or other suitable or equivalent light source),although two or more illumination sources or LEDs may be provided whileremaining within the spirit and scope of the present invention. Circuitelement 32 is attachable at or positioned at a rear portion 24 a ofhousing 24 (such as received at a pocket or receiving portion formed atthe rear portion of the housing 24), whereby the illumination sources 28are located at the rear portion of the housing and at an opposite end ofthe housing from the reflective element 18.

In the illustrated embodiment, signal indication module 22 includeshousing 24 and a rear housing portion or cover element 25 that cooperateto substantially encase the circuit element 32 at the rear portion ofthe housing 24. For example, cover element 25 may snap or may be sealedor adhered or welded to the rear portion of the housing 24 tosubstantially seal circuit element 32 within the housing of the signalindication module. As can be seen in FIG. 4, circuit element 32 includesa pair of electrical terminals or leads 32 a that are in electrical orconductive communication with illumination source 28 and thatelectrically connect the circuitry and light source to electrical poweror electrical control at the mirror assembly when the signal indicationmodule is attached to the back plate and installed at the mirror casing.In the illustrated embodiment, terminals 32 a extend from circuitelement 32 and through notches 24 b formed at the rear portion 24 a ofthe housing 24 and into and/or along a socket portion 34 formed by asocket portion 34 a of housing 24 and a socket portion 34 b of coverelement 25. Socket portion 34 thus provides a socket for a plug or leadof the mirror assembly to readily connect to the signal indicationmodule to provide power and/or control to the signal indication modulewhen the module is mounted to or attached to the back plate andinstalled at the mirror casing.

Signal indication module 22 includes an icon element or indicia element36 that may be disposed at a forward end region or portion 24 c ofhousing 24 so as to be disposed at the rear of the reflective elementwhen the signal indication module 22 is attached to the back plate 20.The indicia element is formed to provide the desired or appropriate iconfor viewing by the driver of the vehicle (for a blind spot detectionsystem application) when the indicia element is backlit by theillumination source 28. Optionally, the walls or surfaces 24 e ofhousing 24 may comprise highly specularly and/or diffusely lightreflecting inner surfaces so as to enhance diffuse reflection ofincident light to enhance the intensity of illumination that exits theindicator module through the indicia element. For example, the diffusewall may be molded of a white plastic material or resin, such as an ABSor an ABS/polycarbonate polymeric resin material or the like.

Optionally, and desirably, a diffuser element 38 is disposed at the rearof the indicia element 36 to diffuse the light emitted by theillumination source 28 to provide more uniform back lighting of theindicia element 36 when the illumination source is activated. Thediffuser element 38 and indicia element 36 may be at least partiallyreceived in the front end portion of the housing 24 and may be attachedand/or sealed thereto. The front end 24 c of housing 24 is formed so asto position indicia element 36 at and preferably against the rearsurface of the reflective element 18 when the module 22 is attached tothe back plate 20.

Back plate 20 is molded or formed, such as by injection molding, so asto provide the display receiving portion 26 and a generally planarbacking portion 20 a that attaches to the rear surface of the reflectiveelement 18 (such as via adhesive or other suitable attachment means). Asshown in FIG. 3, back plate 20 includes an aperture 20 b at mountingportion 26 such that when signal indication module 22 is attached tomounting portion 26 of back plate 20, the front end of housing 24 andthe indicia element 36 of signal indication module 22 are positionedthrough the aperture and at or against the rear surface of thereflective element substrate. Preferably, back plate 20, includingdisplay receiving portion 26, is molded of a substantially dark oropaque or black material, such as from an ABS or polycarbonate polymericresin material or from any other suitable material such as known in theexterior rearview mirror art, so as to be substantially opaque such thatlight does not pass through the opaque back plate and the indicatormounting portion.

As shown in FIGS. 3 and 4, indicator mounting portion 26 is unitarily orintegrally formed with back plate 20 and may be formed with a pocket forreceiving or partially receiving housing 24 to locate signal indicationmodule 22 at the generally planar backing portion 20 a of back plate 20.For example, the pocket may receive housing 24 at least partiallytherein, and the indicator mounting portion 26 may secure (such as bysnapping or the like) the housing at or in the pocket of the indicatormounting portion 26 of back plate 20 (such as via tabs 24 d on housing24 engaging slots or apertures 26 a of mounting portion 26 to snap thesignal indication module 22 to the back plate with the forward end ofthe housing and the indicia element urged toward and against the rearsurface of the reflective element).

Optionally, the back plate may include a perimeter framing portion orbezel portion 20 c that extends around the perimeter edges of thereflective element to support the reflective element and frame thereflective element at the mirror assembly (such as by utilizing aspectsof the mirror assemblies described in U.S. patent application Ser. No.11/520,193, filed Sep. 13, 2006, now U.S. Pat. No. 7,581,859, and/or PCTApplication No. PCT/US07/82099, filed Oct. 23, 2007 and published May 2,2008 as International Publication No. WO 2008/051910, which are herebyincorporated herein by reference in their entireties). The perimeterbezel portion may be narrow or small depending on the particularapplication of the reflective element and mirror reflector sub-assembly.Optionally, the mirror reflector sub-assembly may comprise a bezellessor frameless reflective element (such as the types described in U.S.patent application Ser. No. 11/226,628, filed Sep. 14, 2005 andpublished Mar. 23, 2006 as U.S. Publication No. US-2006-0061008; Ser.No. 10/533,762, filed May 4, 2005, now U.S. Pat. No. 7,184,190; and/orSer. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451,and/or PCT Application No. PCT/US2006/018567, filed May 15, 2006 andpublished Nov. 23, 2006 as International Publication No. WO 2006/124682,which are hereby incorporated herein by reference in their entireties),whereby the back plate may not include a perimeter framing portion orbezel portion around the perimeter of the reflective element.

Back plate 20 may include an attachment element or elements (such as anannular ring or tab or annular prongs or annular snaps or the like)formed or established at the rear of the backing portion 20 a forattaching the back plate 20 and reflective element 18 to a mirroractuator (such as a mirror actuator as known in the art and/or asdescribed in U.S. Pat. Nos. 7,080,914; 7,073,914; 6,916,100; 6,755,544;6,685,864; 6,467,920; 6,362,548; 6,243,218; 6,229,226; 6,213,612;5,986,364 and 5,900,999, which are hereby incorporated herein byreference herein in their entireties), which is adjustable or operableto adjust a viewing angle of mirror reflective element 18. When themirror reflective element is canted or angled partially toward thedriver of the host vehicle (which is typically the orientation of thereflective element during use so as to provide a generally rearwardfield of view to the driver of the host vehicle), there is sufficientspace within the mirror casing at or near the outboard portion of themirror assembly for the indicator mounting portion and signal indicationmodule. The back plate and signal indication module of the presentinvention thus utilizes the space within the mirror head or casing thatis already available and typically not used or occupied by othercomponents.

Illumination source or sources 28 is/are operable or activatable orenergizable to provide illumination at and through or along housing 24,whereby the illumination is transmitted along housing 24 and through thediffusing element 38 and indicia element 36 and through the aperture inback plate 20 and through the reflective element 18 so as to be viewablethrough mirror reflective element 18 by a person viewing the mirrorassembly 10. The signal indication module 22 may comprise a blind spotor object detection indicating device or module that is operable toindicate to the driver of the subject or host vehicle that an object orother vehicle is detected at the side or blind spot region of the hostvehicle by a blind spot detection system, or may comprise a turn signalindicating device or module that is operable to indicate to the driveror passenger of another vehicle that the vehicle is turning or changinglanes, or may comprise other forms or types of display or illuminationor indicating devices or modules, while remaining within the spirit andscope of the present invention.

Illumination source 28 is/are energized to direct or emit illuminationalong housing 24 so that the indicator/light is viewable through thereflective element. The illumination source 28 may comprise any suitableillumination source or light source. For example, the illuminationsource may comprise one or more light emitting diodes (LEDs) or organiclight emitting diodes (OLEDs) or the like, or may comprise one or morepower LEDs, such as of the types described in U.S. Pat. No. 7,195,381,which is hereby incorporated herein by reference in its entirety, or maycomprise a LUXEON® LED available from LUMILEDS™ or other suitable lightsource.

The back plate and/or signal indication module may be formed to providea desired shape for viewing of the light passing through the reflectiveelement or the mirror reflective element may include one or moreiconistic display areas so that the illumination is viewable anddiscernible at the reflective element by the desired or targeted viewer.The mirror assembly thus may provide an iconistic display for an objectdetection/LCA system and/or an iconistic display for a turn signalindication, and/or may provide other displays or illumination devices,without affecting the scope of the present invention.

The indicator mounting portion may be angled so as to direct the lighttoward the vehicle and toward a driver or occupant of the host vehicle.More particularly, the light beam emitted from the blind spot signalindicating module and transmitted through the reflective element isangled so as to have its principle beam axis directed generally towardthe eyes of a driver seated in the interior cabin of the host vehicle.The indicator mounting portion thus may extend from the rear of the backplate at an acute angle (such as approximately about 25 to about 30degrees or thereabouts) relative to the plane defined by the back plateso as to direct or guide light through the passageway and in the desireddirection toward the side of the equipped/host vehicle for viewing theobject/LCA indication principally or solely by the driver of the hostvehicle. Should, however, the signal module be a turn signal module,then the indicator mounting portion may extend from the rear of the backplate at an acute angle (such as approximately about 55 to about 60degrees or thereabouts) relative to the plane defined by the back plateso as to direct or guide light through the passageway and in the desireddirection away from the side of the equipped/host vehicle for viewingthe turn indication principally or solely by the drivers of overtakingvehicles and principally other than by the driver of the host vehicle.

Optionally, it is envisioned that the signal indication module may beformed at an angle that is suitable for either application (blind spotalert and turn signal indication), such as about 30 degrees orthereabouts relative to the rear surface of the mirror substrate. Withsuch a construction, a common module may be used for either applicationby flipping the module or reversing the module so that in one position,the module is angled so as to direct illumination toward the driver ofthe subject vehicle and in the other position, the module is angled soas to direct illumination toward drivers of other vehicles approachingor overtaking the subject vehicle. The indicia element 36 may bereversed as well (depending on the icon or indicia established thereon)or may be selected and added for the particular application (forexample, a warning icon may be provided on modules adapted for use as ablind spot alert while a chevron symbol or the like may be provided onmodules adapted for use as a turn signal indicator). Thus, the differentmodules may have common molded housings and cover elements andcircuitry, and thus may be readily manufactured and supplied for theparticular applications of the vehicles.

Preferably, the mirror reflective element 18 comprises a transflectivedisplay on demand reflective element that is partially transmissive andpartially reflective, so that the light emanating from the signalindication module may be transmitted through the reflective element whenthe illumination source is activated, but the indicator module issubstantially non-visible or viewable when the illumination source isdeactivated. Optionally, the mirror reflective element 18 may comprise asingle substrate or non-electro-optic reflective element (such as shownin FIG. 3), which has a glass substrate with a transflector coating orlayer at its forward surface. Optionally, the reflective element maycomprise an electro-optic, such as electrochromic, reflective element,such as discussed below.

Optionally, a heater pad may be provided at the rear surface of theglass substrate of reflective element and between the backing portion 20a of back plate 20 and the reflective element 18 to provide ananti-fogging of de-fogging feature to the exterior mirror assembly (suchas by utilizing aspects of the heater elements or pads described in U.S.patent application Ser. No. 11/334,139, filed Jan. 18, 2006, now U.S.Pat. No. 7,400,435, which is hereby incorporated herein by reference inits entirety). The back plate and/or heater pad may include suitableelectrical connectors and connections incorporated therein (such as byutilizing aspects of the mirror assembly described in U.S. patentapplication Ser. No. 11/334,139, filed Jan. 18, 2006, now U.S. Pat. No.7,400,435, which is hereby incorporated herein by reference in itsentirety) for electrically connecting the heater pad and/or displayelement (or other suitable electrical connectors may be utilized, suchas electrical leads or wire harnesses or pigtails or other separateconnectors or cables or the like). The heater pad may include a hole oropening or aperture therethrough (or optionally a window or transparentor translucent or diffuse portion of the heater pad, such as a clear ordiffusing transparent polyester flexible plastic film or element) thatgenerally corresponds to the aperture 20 b of back plate 20 when theheater pad is attached to the rear surface of the glass substrate ofreflective element 18 and when the back plate 20 is attached to the rearsurface of the heater pad. Optionally, and desirably, the heater pad mayinclude an adhesive layer (such as a pressure sensitive adhesive layer)at its rear surface for adhering the back plate to the heater pad andthus to the rear surface of the glass substrate of the reflectiveelement 18.

Optionally, and preferably, indicator element or display element orsignal indication module 22 may snap into the end or pocket of theindicator mounting portion 26 or may otherwise be attached or stuck atthe indicator mounting portion, and may have a gasket or seal at thesignal indication module to provide a substantially water proof or waterresistant or water tight seal at the signal indication module, wherebythe signal indication module may be sealed at the indicator mountingportion, such as by gluing or pressing or screwing or gasketing orhermetically sealing or otherwise substantially sealing the signalindication module at the indicator mounting portion. The signalindication module may comprise a self-contained, unitary, sealed orsubstantially sealed, indicator module that includes the housing andcover element, an illumination source (such as one or more LEDs or thelike), a DC converter with a voltage dropping resistor (such asdescribed in U.S. Pat. Nos. 6,902,284 and 6,690,268 and/or U.S. patentapplication Ser. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat. No.7,195,381, which are hereby incorporated herein by reference in theirentireties) and the electrical terminals or connector. The signalindication module thus may be connected to a power source and may beactivated or energized to illuminate the display for viewing by thedriver of the vehicle. Optionally, the electrical connections to thesignal indication module may be made while the signal indication moduleis attached to the mirror assembly, such as via a plug and socket typearrangement or configuration, and such as by utilizing aspects of themirror assembly described in U.S. Pat. No. 6,669,267, which is herebyincorporated herein by reference in its entirety. The unitary signalindication module may include or utilize aspects of various lightmodules or systems or devices, such as the types described in U.S. Pat.Nos. 6,227,689; 6,582,109; 5,371,659; 5,497,306; 5,669,699; 5,823,654;6,176,602 and/or 6,276,821, and/or U.S. patent application Ser. No.11/520,193, filed Sep. 13, 2006, now U.S. Pat. No. 7,581,859, and/or PCTApplication No. PCT/US2006/018567, filed May 16, 2006 and published Nov.23, 2006 as International Publication No. WO 2006/124682, which arehereby incorporated herein by reference in their entireties.

Optionally, the signal indication module may be supplied or provided toan assembly facility (such as a mirror assembly facility or the like)from a module supplier while the back plate may be supplied or providedto the assembly facility from a back plate supplier. An operator at theassembly facility may attach the module to the back plate, preferably bysnapping or pressing the module to the back plate to assemble the moduleto the back plate (whereby the module may have a snug fit within thereceiving portion or pocket such that the module and back plate arepreferably substantially water impervious). Optionally, and desirably,electrical connection (such as to a power supply or 12 volt power wireof the vehicle battery/ignition system or to a power feed from a LIN buscontroller) to the module may be made when the module is snapped orotherwise attached (preferably mechanically but optionally adhesively)to the back plate (such as by making electrical contact between themodule and mirror circuitry [including circuitry associated with thereflective element and/or mirror assembly, such as electrochromic mirrorcircuitry, mirror lights and display circuitry and the like, typicallydisposed at a printed circuit board of the mirror assembly] when themodule is snapped to the back plate, such as by press attaching thedisplay module into receiving fingers or clips or snaps or the like thatare integrally formed with the back plate in the injection moldingoperation that manufactures or forms the back plate itself) oralternately, electrical connection to the module may be made via othermeans, such as wires or leads or the like before or after the module issnapped or attached to the back plate.

Optionally, and with reference to FIGS. 9-11, a mirror reflectorsub-assembly 12′ for an exterior vehicular mirror includes a mirrorreflective element 18′ and a mirror reflector carrier or back plate 20′attached to or mounted to or adhered to a rear surface 18 a′ of mirrorreflective element 18′. The mirror reflector sub-assembly 12′ includesan indicator or display element or device or signal indication module22′ that is disposed at back plate 20′ and behind reflective element18′, and that is operable to provide a display or indication at thereflective element for viewing the display or indication through themirror reflective element, such as in a similar manner as describedabove with respect to signal indication module 22. Signal indicationmodule 22′ includes a housing 24′ (that is received into or attached toan indicator receiving portion or mounting portion or structure 26′ ofback plate 20′ so as to be disposed generally at a rear surface of aplanar portion 20 a′ of back plate 20′) and an illumination source orindicator 28′, such as one or more light emitting diodes (LEDs) or othersuitable illumination source. In the illustrated embodiment, the mirrorassembly includes a signal indication module 22′ for an object detectionin a blind spot detection system or LCA system (with the indicatormodule being angled and operated to provide a signal that is principallyviewable by the driver of the vehicle), but could also or otherwiseinclude a display device for a turn signal indicator or signalindication module or other indicator device (as also discussed below).The indicator element or signal indication module thus may be readilymounted to or attached to an indicator mounting portion of the backplate 20′, such as discussed above.

Signal indicator module 22′ may be substantially similar to signalindicator module 22, discussed above, such that a detailed discussion ofthe signal indicator modules need not be repeated herein. As shown inFIG. 9, signal indication module 22′ includes housing 24′ and a rearhousing portion or cover element 25′ that cooperate to substantiallyencase the circuit element 32′ at the rear portion of the housing 24′.As can be seen in FIG. 9, circuit element 32′ includes a pair ofelectrical terminals or leads 32 a′ that are in electrical or conductivecommunication with illumination source 28′ and that electrically connectthe circuitry and light source to electrical power or electrical controlat the mirror assembly when the signal indication module is attached tothe back plate and installed at the mirror casing. In the illustratedembodiment, terminals 32 a′ extend from circuit element 32′ and throughnotches 24 b′ formed at the rear portion 24 a′ of the housing 24′ andinto and/or along a socket portion 34′ formed by a socket portion 34 a′of housing 24′ and a socket portion 34 b′ of cover element 25′. Socketportion 34′ thus provides a socket for a plug or lead of the mirrorassembly to readily connect to the signal indication module to providepower and/or control to the signal indication module when the module ismounted to or attached to the back plate and installed at the mirrorcasing.

Signal indication module 22′ includes an icon element or indicia element36′ that may be disposed at a forward end region or portion 24 b′ ofhousing 24′ so as to be disposed to the rear of the reflective elementwhen the signal indication module 22′ is attached to the back plate 20′.The indicia element is formed to provide the desired or appropriate iconfor viewing by the driver of the vehicle (such as, for example, for ablind spot detection system application) when the indicia element isbacklit by the illumination source 28′. Optionally, and desirably, alight diffusing element may be disposed in front of or at the rear ofthe indicia element 36′ (and may be a separate element or substrate orfilm or may be integral with the indicia element) to further diffuselight emitted by the illumination source 28′ passing therethrough, inorder to provide enhanced uniformity of back lighting of the indiciaelement 36′ when the illumination source is activated. The indiciaelement 36′ may be at least partially received in the front end portionof the housing 24′ and may be attached and/or sealed thereto. The frontend 24 c′ of housing 24′ is formed so as to position indicia element 36′at and preferably against the rear surface of the reflective element 18′when the module 22′ is attached to the back plate 20′.

In the illustrated embodiment, indicia element 36′ and/or the diffuserelement comprise a circular element that is disposed at the front endportion of housing 24′. Housing 24′ includes an outer wall 24 e′ thatsupports and/or receives the circuit element 32′ and cover element 25′at its rearward end and an inner wall or guide wall 24 f′. As can beseen in FIGS. 9 and 11, inner wall 24 f′ has a rearward end thatreceives or aligns with the illumination source or sources of circuitelement 32′ and a forward end that receives or aligns with the indiciaelement 36′. Inner wall 24 f′ is a conical-shaped wall and is angled (asshown in FIG. 11) so as to direct light emitted by the illuminationsource toward and through the indicia element 36′. The indicia elementmay provide any suitable alert or indicator, such as a triangular-shapedalert or an exclamation point alert (or an exclamation point within atriangular-shaped border as shown in the illustrated embodiment) or thelike for a blind spot indicator system (or other suitable alert orindicator for other applications, such as an arrow head or chevron iconor the like for turn signal indicator applications), that is viewableand discernible and understandable by the person viewing the indicia atthe reflective element of the exterior rearview mirror assembly.

The conical-shaped inner wall 24 f′ of housing 24′ is angled so as toguide the illumination in the desired direction, such as toward the sideof the vehicle for a blind spot indicator application (or away from theside of the vehicle for a turn signal indicator application or thelike). Preferably, the inner wall or surfaces 24 f′ is highly specularlyand/or diffusely light reflecting so as to enhance diffuse reflection ofincident light to enhance the intensity of illumination that exits theindicator module through the indicia element. Preferably, the diffusewall is molded of a white plastic material or resin, such as an ABS oran ABS/polycarbonate polymeric resin material or the like.

Optionally, and as discussed above, the signal indication module may besupplied or provided to an assembly facility (such as a mirror assemblyfacility or the like) from a module supplier, while the back plate maybe supplied or provided to the assembly facility from a back platesupplier. An operator or operators at the assembly facility may attachor adhere the back plate (which may include a heater pad disposedthereat or the operator may attach or adhere a heater pad to the backplate and/or reflective element) to the rear surface of the reflectiveelement, and the signal indicator module may be attached to the backplate, preferably by snapping or pressing the module to the back plateto assemble the module to the back plate (whereby the module may have asnug fit within the receiving portion or pocket such that the module andback plate are preferably substantially water impervious). Optionally,and desirably, electrical connection to the signal indicator module maybe made when the module is snapped or otherwise attached (preferablymechanically but optionally adhesively) to the back plate, such as bymaking electrical contact between the module and mirror circuitry (suchas circuitry associated with the reflective element and/or mirrorassembly, such as electrochromic mirror circuitry, mirror lights anddisplay circuitry and the like, typically disposed at a printed circuitboard of the mirror assembly) when the module is snapped to or attachedto the back plate, such as by press attaching the signal indicatormodule into receiving fingers or clips or snaps or the like that areintegrally formed with the back plate in the injection molding operationthat manufactures or forms the back plate itself, or alternately,electrical connection to the module may be made via other means, such aswires or leads or the like before or after the module is snapped orattached to the back plate.

With reference to FIGS. 12A-C, the indicator module may be approximately28 mm by about 36.3 mm, with a height or depth of about 20.1 mm. Theouter walls of the housing may be generally rectangular-shaped and maybe approximately 24 mm wide by 21 mm wide. In the illustratedembodiment, the rearward end of the housing is angled at approximately30 degrees so as to angle or cant the circuit element at that angle toemit the illumination in the desired angle, such as generally rearwardand toward the side of the vehicle for viewing by the driver of thevehicle (for blind spot indicator applications) or generally rearwardand away from the side of the vehicle for viewing by drivers of othervehicles (for turn signal indicator applications). The exemplaryembodiment of FIGS. 12A-C is provided to show an example of thedimensions of the signal indicator module of the present invention, butdimensions may be implemented without affecting the scope of the presentinvention.

Optionally, and with reference to FIGS. 13-15, a mirror reflectorsub-assembly 52 for an exterior vehicular mirror includes a mirrorreflective element 58 and a mirror reflector carrier or back plate 60attached to or mounted to or adhered to a rear surface 58 a of mirrorreflective element 58, with an indicator or display element or device orsignal indication module 62 that is disposed at back plate 60 and behindreflective element 58, and that is operable to provide a display orindication at the reflective element for viewing the display orindication through the mirror reflective element, such as in a similarmanner as described above with respect to signal indication modules 22,22′.

Signal indication module 62 includes a housing 64 (that is received intoor attached to an indicator receiving portion or mounting portion orstructure 66 of back plate 60 so as to be disposed generally at a rearsurface of a planar portion 60 a of back plate 60) and an illuminationsource or indicator 68, such as one or more light emitting diodes (LEDs)or other suitable illumination source on a circuit element 72, such as aprinted circuit board or substrate or the like. In the illustratedembodiment, the mirror assembly includes a signal indication module 62for a turn signal indicator or signal indication module, but could alsoor otherwise include a display device for an object detection in a blindspot detection system or LCA system (with the indicator module beingangled and operated to provide a signal that is principally viewable bythe driver of the vehicle) or other indicator device.

In the illustrated embodiment, housing 64 includes a plurality ofapertures or passageways 64 g therethrough that are defined by innerwalls or surfaces 64 f, which may comprise conical-shaped angled wallsor surfaces to align with the respective illumination sources of thecircuit element and to direct or guide the emitted light toward andthrough the reflective element at the forward end of the housing. As canbe seen in FIG. 15, the passageways 64 g may receive the respectiveillumination source 68 at their rearward ends and may guide the emittedillumination toward and through the reflective element at the forwardend of the housing 64, such as in a similar manner as described above.Optionally, the signal indicator module may include an indicia elementand/or a diffusing element at the forward end of the housing and betweenthe housing and the rear surface of the reflective element, depending onthe particular application of the signal indicator module and thedesired display or indicia or pattern to be viewed at the mirrorassembly.

Optionally, and desirably, the circuit element 72 may include a pair ofelectrical terminals or leads 72 a that are in electrical or conductivecommunication with illumination sources 68 and that electrically connectthe circuitry and light sources to electrical power or electricalcontrol at the mirror assembly when the signal indication module isattached to the back plate and installed at the mirror casing. In theillustrated embodiment, terminals 72 a extend from circuit element 72and through a notch or notches 65 a formed at the rear cover 65 andextend outward for electrical connection to a socket portion orelectrical connector 74 at the back plate 60. The socket portion 64 thusmay provide a socket for a plug or lead of the mirror assembly toreadily connect to the signal indication module to provide power and/orcontrol to the signal indication module when the module is mounted to orattached to the back plate and installed at the mirror casing.

Optionally, and as discussed above, the signal indication module may besupplied or provided to an assembly facility (such as a mirror assemblyfacility or the like) from a module supplier, while the back plate maybe supplied or provided to the assembly facility from a back platesupplier, and an operator or operators at the assembly facility mayattach or adhere the back plate (which may include a heater pad disposedthereat or the operator may attach or adhere a heater pad to the backplate and/or reflective element) to the rear surface of the reflectiveelement, and the signal indicator module may be attached to the backplate, preferably by snapping or pressing the module to the back plateto assemble the module to the back plate (whereby the module may have asnug fit within the receiving portion or pocket such that the module andback plate are preferably substantially water impervious). Optionally,and desirably, electrical connection to the signal indicator module maybe made when the module is snapped or otherwise attached (preferablymechanically but optionally adhesively) to the back plate, such as in asimilar manner as described above.

Optionally, and with reference to FIG. 16, a mirror reflectorsub-assembly 52′ for an exterior vehicular mirror includes a mirrorreflective element 58′ and a mirror reflector carrier or back plate 60′attached to or mounted to or adhered to a rear surface 58 a′ of mirrorreflective element 58′, with an indicator or display element or deviceor signal indication module 62′ that is disposed at back plate 60′ andbehind reflective element 58′, and that is operable to provide a displayor indication at the reflective element for viewing the display orindication through the mirror reflective element, such as in a similarmanner as described above.

Signal indication module 62′ includes a housing 64′ (that is receivedinto or attached to an indicator receiving portion or mounting portionor structure 66′ of back plate 60′ so as to be disposed generally at arear surface of a planar portion 60 a′ of back plate 60′) and a rearcover element 65′ and an illumination source or indicator, such as oneor more light emitting diodes (LEDs) or other suitable illuminationsource on a circuit element 72′, such as a printed circuit board orsubstrate or the like, disposed and sealed within housing 64′ and coverelement 65′. In the illustrated embodiment, the mirror assembly includesa signal indication module 62′ for a turn signal indicator or signalindication module, but could also or otherwise include a display devicefor an object detection in a blind spot detection system or LCA system(with the indicator module being angled and operated to provide a signalthat is principally viewable by the driver of the vehicle) or otherindicator device.

In the illustrated embodiment, the housing 64′ provides an inner wall 64f′ that defines a passageway 64 g′ therethrough. A diffuse glow bar orblock or element 67′ (such as an arrow head-shaped element orchevron-shaped element or the like for turn signal indicatorapplications) is received within or at passageway 64 g′ so that lightemitted by the illumination source or sources of the circuit element 72′passes through the glow element 67′, whereby the glow element provides agenerally uniformly illuminated element for viewing through thereflective element. The glow element may comprise a translucent ordiffuse element, such as a diffuse acrylic element or the like, and/ormay utilize aspects of the glow blocks or elements described in PCTApplication No. PCT/US2006/018567, filed May 15, 2006 and published Nov.23, 2006 as International Publication No. WO 2006/124682, and/or PCTApplication No. PCT/US07/82099, filed Oct. 23, 2007 and published May 2,2008 as International Publication No. WO 2008/051910, which are herebyincorporated herein by reference in their entireties.

Glow element 67′ thus is a light transmitting and light diffusingelement (such as may be formed from a light diffusing acrylic orpolycarbonate molding), which may be rendered diffuse, such as byroughening or stippling of at least a portion of or all of the exteriorsurface of the block or element, or may be rendered diffuse during themolding or forming of the block or element, such as by utilizingcrystalline materials or other light scattering effects or techniques inthe molding (such that the light diffusing properties or characteristicsof the glow element are created intrinsically). Optionally, glow element67′ may have its side walls diffusely light reflecting or specularlylight reflecting and/or the inner wall or walls 64 f′ of the housing 64′may be diffusely or specularly light reflecting so that light rays thatmay otherwise be absorbed by the housing will reflect or bounce back andpass through the glow block or element and out through reflectiveelement.

Optionally, the glow element may have a varying thickness (as can beseen in FIG. 16, the center region of the element is thicker than theouter or end regions of the element), and the circuit element may be agenerally planar substrate or may be a flexible substrate (such as bydisposing the LEDs on a flexible polymer printed circuit film or on athin metal flexible printed metallic film or circuit) or a bentsubstrate or element, in order to dispose or locate or provide theillumination sources at about the same distance from (or generallyuniformly at) the rear surface of the glow element. In applicationswhere some of the illumination sources (such as the illumination sourcesat or near the outer ends of the glow element) are closer to thereflective element, the signal indicator module may provide non-uniformflooding of the glow element. In the illustrated embodiment, the glowelement has a generally planar base or forward surface and an angledrear surface. The glow element may be disposed so that its generallyplanar forward surface is at or near or opposed to the rear surface ofthe reflective element, while the angled rear surface is angled relativeto the rear surface of the reflective element. The circuit element maybe located or disposed at the angled rear surface of the glow elementand may be angled or bent or formed so that the LEDs are positionedgenerally at or near the angled rear surface of the glow element. Thevarying thickness of the glow element (being thicker at its centralregion and thinner at or toward its end regions) thus may compensate forthe position of the LEDs relative to the glass of the reflective elementto provide enhanced uniformity of the light passing through the glowelement and the reflective element. Optionally, enhanced uniformity oflight passing through the glow element and the reflective element may beaccomplished by driving the LEDs at a different current or intensity,depending on the location of the individual LEDs at or along the angledor varying thickness glow element.

Optionally, and as discussed above, the signal indication module may besupplied or provided to an assembly facility (such as a mirror assemblyfacility or the like) from a module supplier, while the back plate maybe supplied or provided to the assembly facility from a back platesupplier, and an operator or operators at the assembly facility mayattach or adhere the back plate (which may include a heater pad disposedthereat or the operator may attach or adhere a heater pad to the backplate and/or reflective element) to the rear surface of the reflectiveelement, and the signal indicator module may be attached to the backplate, preferably by snapping or pressing the module to the back plateto assemble the module to the back plate (whereby the module may have asnug fit within the receiving portion or pocket such that the module andback plate are preferably substantially water impervious). Optionally,and desirably, electrical connection to the signal indicator module maybe made when the module is snapped or otherwise attached (preferablymechanically but optionally adhesively) to the back plate, such as in asimilar manner as described above.

Thus, the present invention provides signal indicator modules thatprovide enhanced viewing of the indicia or shape to be viewed at thereflective element of the exterior rearview mirror assembly. In knownapplications where a window is laser ablated or otherwise establishedthrough the reflective coating of the reflective element, the size ofsignal indicators is limited because the mirror reflector does notreflect in the areas where the indicator is disposed. However, byincorporating the signal indicator modules of the present invention withdisplay on demand transflective reflective elements, the illuminationmay transmit through the transflective reflective element for viewing bythe person viewing the illuminated indicia or shape when the module isactivated or energized, but the mirror reflector reflects light incidentthereon so that the presence of the indicator module is not discerniblewhen the indicator module is not activated or energized. Thus, thesignal indicator module of the present invention may provide a largerdisplay or indicia or illuminated shape or form than the prior artdevices without detracting from the reflectance of the mirror reflectiveelement (for example, the width of the chevron indicia may be at least 2mm and even up to 4 mm or more, without adversely affecting thereflectance of light incident on the mirror reflective element), andthus the present invention provides enhanced signal indicator modulesfor use in blind spot indicator systems and/or turn signal indicatorsystems and/or the like.

Optionally, other forms of signal indication modules may be provided ata formed back plate, such as a signal indication module having atransparent or diffuse block or element (such as the types described inPCT Application No. PCT/US2006/018567, filed May 15, 2006 and publishedNov. 23, 2006 as International Publication No. WO 2006/124682, and/orPCT Application No. PCT/US07/82099, filed Oct. 23, 2007 and publishedMay 2, 2008 as International Publication No. WO 2008/051910, which arehereby incorporated herein by reference in their entireties) disposed ata mounting portion of a back plate, or an elongated hollow tube (such asthe types described in U.S. patent application Ser. No. 11/520,193,filed Sep. 13, 2006, now U.S. Pat. No. 7,581,859; and/or Ser. No.11/226,628, filed Sep. 14, 2005 and published Mar. 23, 2006 as U.S.Publication No. US-2006-0061008, and/or PCT Application No.PCT/US07/82099, filed Oct. 23, 2007 and published May 2, 2008 asInternational Publication No. WO 2008/051910, which are herebyincorporated herein by reference in their entireties) disposed at orformed with the back plate. For example, and with reference to FIG. 5, aback plate 120 is molded or formed to provide a mounting portion orreceiving portion 126 a for mounting turn signal indicator module 122 athereat and a second mounting portion or receiving portion 126 b formounting a blind spot indicator module 122 b thereat. In the illustratedembodiment, turn signal indicator module 122 a includes a transparent ortranslucent optical plastic block 140, with an illumination source 128 aat a rear portion of the block and a light control film 141 disposed atthe front portion of the block, and with the block mounted at the rearend region of an angled light directing element or tube 142 a (which maybe formed with the mounting portion 126 a of back plate 120, or may besnapped to or otherwise mounted to or connected to the mounting portion126 a of back plate 120, so as to be generally aligned with an aperture146 a in back plate). Blind spot indicator module 122 b includes anillumination source 128 b disposed at a rear end region of a hollow tubeportion 142 b (which may be formed with mounting portion 126 b of backplate 120, or may be snapped to or otherwise mounted to or connected tothe mounting portion 126 b of back plate 120, so as to be generallyaligned with an aperture 146 b in back plate). The signal indicatormodules 122 a, 122 b may utilize aspects of the modules described inU.S. patent application Ser. No. 11/520,193, filed Sep. 13, 2006, nowU.S. Pat. No. 7,581,859; and/or Ser. No. 11/226,628, filed Sep. 14, 2005and published Mar. 23, 2006 as U.S. Publication No. US-2006-0061008,and/or PCT Application No. PCT/US2006/026148, filed Jul. 5, 2006 andpublished Jan. 11, 2007 as International Publication No. WO 2007/005942,and/or PCT Application No. PCT/US2006/018567, filed May 15, 2006 andpublished Nov. 23, 2006 as International Publication No. WO 2006/124682,and/or PCT Application No. PCT/US07/82099, filed Oct. 23, 2007 andpublished May 2, 2008 as International Publication No. WO 2008/051910,which are hereby incorporated herein by reference in their entireties.

As shown in FIG. 5, the tube portions 142 a, 142 b each provide anangled passageway 144 a, 144 b, respectively, that is angled in thedesired or appropriate direction relative to the generally planarportion or attaching portion 120 a of back plate 120 (such as toward theside of the vehicle to which the mirror is mounted for the blind spotindicator module 122 b and away from the side of the vehicle to whichthe mirror is mounted for the turn signal indicator module 122 a). Inthe illustrated embodiment, the translucent block 140 is disposed at orreceived in the rear portion of the tube portion 142 a such that thefront surface of the block (with the light control film 141 disposedthereat) is generally parallel with the generally planar portion of theback plate 120. Similarly, the illumination source 128 b may be disposedat a circuit element or circuit board 129 that is disposed at orreceived in the rear portion of the tube portion 142 b such that thecircuit element 129 is generally parallel with the generally planarportion of the back plate 120. Thus, illumination from the illuminationsources 128 a, 128 b is directed generally toward the back plate and isangled or reflected via the inner walls of the passageways 144 a, 144 bso as to exit the back plate and transmit through the mirror reflectiveelement in the desired or appropriate direction. Optionally, the lightdirecting film 141 may function to angle or direct the light beingtransmitted through translucent or diffuse block 140 in a directiongenerally along the passageway 144 a.

In the illustrated embodiment, tube portion 142 b may be angled relativeto the back plate 120, and may be bent at a rearward portion of the tube142 b. As can be seen in FIG. 5, the tube portion 142 b thus includes aforward angled portion 143 a at the rear of the back plate 120 and arearward angled portion 143 b at the rearward end of the forward angledportion 143 a and at a different angle relative to the back plate 120.In the illustrated embodiment, the rearward angled portion 143 b isgenerally normal to or perpendicular to the generally planar back plateportion 120 a, such that the illumination source is disposed so as to begenerally aligned with the passageway of the rearward angled portion andemitting light generally toward and perpendicular to the planar portionof the back plate. Likewise, a receiving portion or passageway 145 isformed or established at the rear portion of the tube portion 142 a andreceives block 140 therein. Because receiving passageway 145 isgenerally normal to or perpendicular to the generally planar portion 120a of back plate 120, block 140 is oriented to be generally parallel toplanar portion 120 a of back plate 120 when received in receivingpassageway 145.

Optionally, and desirably, the illumination source 128 a may comprise asingle light emitting diode, such as a power LED, such as of the typesdescribed in U.S. Pat. No. 7,195,381, which is hereby incorporatedherein by reference in its entirety. Optionally, one or more lightemitting diodes (or other suitable light source) may be provided at thecap wall (or rear wall or end of the tube portion) or optionally at aside wall of the tube portion and/or translucent block, such as byutilizing aspects of the indicator modules described in PCT ApplicationNo. PCT/US07/82099, filed Oct. 23, 2007 and published May 2, 2008 asInternational Publication No. WO 2008/051910, which is herebyincorporated herein by reference in its entirety. Likewise, theillumination source 128 b may comprise one or more light emitting diodesand may be disposed at the cap wall or rear end portion of the tubeportion or at a side wall of the tube portion, while remaining withinthe spirit and scope of the present invention.

Optionally, and with reference to FIG. 6, a back plate 120′ is molded orformed to provide a mounting portion or receiving portion 126 a′ formounting turn signal indicator module 122 a′ thereat and a secondmounting portion or receiving portion or tube structure 126 b′ formounting a blind spot indicator module 122 b′ thereat. Turn signalindicator module 122 a′ includes a transparent or translucent opticalplastic block 140′, an illumination source 128 a′ at a rear portion ofthe block and a light control film 141′ disposed at the front portion ofthe block (such as similar to indicator module 122 a discussed above),with the block mounted at the rear end region of an angled lightdirecting element or tube 142 a′. Blind spot indicator module 122 b′includes an illumination source 128 b′ disposed at a rear end region ofa hollow tube portion 142 b′ (such as similar to indicator module 122 adiscussed above). As shown in FIG. 6, the rear receiving passageway 145′(that receives block 140′ therein) is angled so that the rear receivingpassageway 145′ is angled relative to the tube portion 142 a′ andrelative to back plate 120′, whereby block 140′ is angled relative tothe planar portion 120 a′ of back plate 120′.

As also shown in FIG. 6, the tube portion 142 b′ for the blind spotindicator module 122 b′ may comprise a zig-zag or bent tube, with therearward angled portion 143 b′ of tube portion 142 b′ being angledrelative to the forward angled portion 143 a′ so as to be angledrelative to (and not normal to) the generally planar back plate portion120 a′ and in a direction outboard and away from the side of the vehicleto which the mirror is mounted, while the forward angled portion 143 a′of tube portion 142 b′ is angled relative to the generally planar backplate portion 120 a′ and in a direction inboard and toward the side ofthe vehicle to which the mirror is mounted. In the illustratedembodiment, the circuit element 129′ and illumination source 128 b′ aredisposed at the rearward end of the rearward angled portion 143 b′ andare angled relative to the back plate portion 120 a′ so as to bedirected along the passageway of the rearward angled portion. Thezig-zag configuration of the tube may allow for a lower profile tubeportion while achieving the desired directionality and uniformity oflight emanating from the tube portion and through the reflectiveelement. The signal indication modules 122 a′ and 122 b′ of FIG. 6 mayotherwise be similar to those described above, such that a detaileddiscussion of the signal indication modules need not be repeated herein.

Optionally, and with reference to FIGS. 7 and 7A, a signal indicationmodule 122 b″ may have the rear end portion of the rearward angledportion 143 b″ of tube portion 142 b″ angled or formed to receive ormount circuit element 129″ and illumination source 128 b″ thereat suchthat the illumination source is disposed or oriented generally parallelto the generally planar portion 120 a′ of back plate 120′. As can beseen in FIG. 7A, such an arrangement causes the light emitting from theillumination source (with the light emitted generally toward the sidewall of the tube portion) to reflect off of the inner walls of the tubeand reflect along the bent passageway, which assists in directing andaligning the light rays so that the light is generally uniformly emittedfrom the tube and through the reflective element and the light isdirected or guided in the desired direction as it exits the tube portionand passes through the reflective element of the mirror assembly (wherethe light exits at an angle so as to be principally viewable by thedriver of the host vehicle and not readily viewable by others, such asdrivers of other vehicles in the lane adjacent to the host vehicle). Theaperture through the back plate may be generally aligned with theforward tube portion so as to augment the directionality of the lightemanating therefrom. The signal indication modules 122 a′ and 122 b″ ofFIG. 7 may otherwise be similar to those described above, such that adetailed discussion of the signal indication modules need not berepeated herein.

Optionally, and with reference to FIG. 8, a blind spot signal indicationmodule 222 b may include a generally straight tube portion 242 b that isangled relative to the planar portion 220 a of the back plate 220, whilethe aperture 246 b formed in the back plate may be angled or canted atthe same angle as the tube passageway (such as discussed above) or at adifferent angle than the angle of the passageway formed through the tubeportion 242 b (such as shown in FIG. 8). Thus, light emitting from theforward end of the tube portion 242 b (via passage along the passageway244 b of tube portion 242 b) may be angled or directed or guided via theangled aperture 246 b so as to be directed or guided in the desired orappropriate direction (such as generally toward the side of the vehicleto which the mirror is mounted so as to be principally viewable by thedriver of the vehicle). The signal indication modules 222 a and 222 b ofFIG. 8 may otherwise be similar to those described above, such that adetailed discussion of the signal indication modules need not berepeated herein.

Optionally, an icon or indicia or pattern that defines the display (suchas backlit by the illumination source of the signal indication modulewhen the illumination source is activated) may be established at therear of the rear substrate and between the rear surface of the rearsubstrate and signal indication module. The icons or pattern that definethe display may be established through or defined by a dark layer oropacifying layer at the rear of the mirror substrate so that icons oriconistic portions of the dark layer form the icon or icons of theiconistic display area. Optionally, the iconistic portions of thedisplay area may be established by etching the dark layer or by a maskor the like positioned at the rear surface of the substrate during thepainting or screening or coating process that applies a dark layer.Optionally, the iconistic portions of the display area may beestablished by etching or masking at a fourth surface conductive busbaror coating (such as a fourth surface conductive busbar of the typesdescribed in U.S. patent application Ser. No. 11/021,065, filed Dec. 23,2004, now U.S. Pat. No. 7,255,451; and/or Ser. No. 11/334,139, filedJan. 18, 2006, now U.S. Pat. No. 7,400,435; and/or U.S. provisionalapplications, Ser. No. 60/644,903, filed Jan. 19, 2005; and Ser. No.60/667,049, filed Mar. 31, 2005, which are hereby incorporated herein byreference in their entireties). Optionally, the icons or pattern may beestablished via cutouts or holes or patterns or indicia portions formedin and through or partially through a heater pad (that may be attachedto or adhered to the dark or opacifying layer at the rear surface of thereflective element, as discussed below), with the dark layer having anopening or aperture formed therethrough and generally corresponding withthe indicia portions of the heater pad when the heater pad is adhered tothe dark layer at the rear surface of the reflective element.

Optionally, the mirror reflector sub-assembly may include masks orbaffles or additional light direction means or occluding means ordirectional filtering. For example, the mirror reflective elementsub-assembly may comprise louvers or shutters for shading from view, orfilters or light directing film or the like, at the rear of thereflective element (such as between the back plate and the iconisticportions) for further directing or guiding the illumination from theillumination source at the desired angle and through the reflectiveelement so as to be principally or solely viewable by the driver of thehost vehicle (for blind spot/LCA applications) or so as to beprincipally or solely viewable by others at the side or rear of thevehicle but not principally by the host driver (for turn signalapplications).

Therefore, the present invention provides a back plate that includes oneor more indicator mounting portions or display receiving portionsintegrally formed therewith, so that the display element or device maybe readily assembled to the mirror reflector sub-assembly via attachmentor adherence of the back plate to the mirror reflective element. Thepresent invention thus provides a display element or device that isreadily assembled to a mirror reflector sub-assembly, and thusfacilitates assembly of the mirror reflector sub-assembly at a facilityremote from the mirror assembly facility, such that the mirror reflectorsub-assembly (including the back plate and indicator mounting portion)may be provided or supplied to the mirror manufacturer as a unit. Themirror manufacturer then may install or attach the indicator orindicator module to the indicator mounting or receiving portion (or mayelectrically connect the terminals of an already installed indicator toa wire or lead of the mirror assembly), and may attach the mirrorreflector sub-assembly to the mirror actuator. The present inventionthus provides enhanced assembly processing of the mirror assembly, whiletaking advantage of the otherwise typically unused space within thecasing and behind the back plate of the exterior rearview mirrorassembly. For example, a mirror manufacturer may purchase a sealed,pre-assembled signal indicator module (including the necessaryelectrical connectors for establishing electrical connection and powerand control to the module as it is attached or mounted to the reflectiveelement or back plate), and may insert the module into the housing orshell or structure of the back plate (that is pre-configured to receivesuch) or may otherwise engage the module with the rear of the reflectiveelement assembly, such as by inserting one end of the module into theside walls of the shell or structure of the back plate and against therear of the reflective element, whereby the module makes an at leastpartially efficient optical connection/coupling to the rear surface orportion of the transflective reflective element or to a lighttransmitting portion of any heater pad disposed between the back plateand the rear of the reflective element, preferably while also making amechanical connection and alignment to the back plate of the reflectiveelement assembly. Note that the receiving portion of the back plate atthe rear of the heater pad/reflective element and where the signalindicator/light unit emits light therethrough when its light source orlight sources are activated may itself comprise a resilient lighttransmitting clear and/or light-diffusing material or element (such as alow durometer soft plastic material or element, such as an elementhaving less than 120 Shore A durometer hardness for example, such as asilicone pad or film, or such as an optical adhesive or optical tape orfilm) that at least one of (a) light-couples the receiving part of theback plate to the signal indicator/light unit and (b) light couples thepart of the back plate where the signal indicator/light unit is disposedat (and emits light through) to the corresponding aperture or lighttransmitting window of the heater pad and/or to the rear surface of thesubstrate of the reflective element.

Optionally, a spring-like resilient light transmitting and/or lightdiffusing interface or pad, such as a silicone or other soft or pliableplastic having light transmitting qualities, may be provided at theinterface end of the module (or at or in any aperture in the back platewhere a light indicator shines through) to provide an interface at therear (typically a glass surface that may be coated or uncoated) of thereflective element with little or no air gap between the module and therear of the reflective element. Also, the indicator module (having ashape or structure, such as a triangular or trapezoid shape or the like,with one or more light sources or light emitting diodes and anelectrical connector) may have a light transmitting element or window orlens (that may or may not have an optical light directing property) atits interfacing end that is at least somewhat soft or pliable, so thatthe module creates intimate contact at the rear of the reflectiveelement when pressed against the reflective element. The module may bepurchased with the light transmitting interface or pad alreadyincorporated therein, or the pad may be a separate element at the rearof the reflective element or may be separately disposed between themodule and the rear of the reflective element.

The signal indicator or blind spot indicator or turn signal indicator ofthe present invention thus provides a visible signal that is viewable atthe exterior mirror by a person viewing the reflective element of theexterior rearview mirror at or near an appropriate angle or locationrelative to the exterior mirror. If the mirror reflective element is nota transflective mirror reflective element (such as a construction usinglaser ablation to create a hole or holes in the mirror reflector such asis now used on the likes of 2008 Toyota Tundra and 2008 CadillacEscalade vehicles), the size of the icon or indicia of the display orsignal indicator module is typically limited if used for blind spotindication, such as to a size dimension that is circumscribed by acircle having a diameter of about 5 mm to about 7 mm or less, since alarger indicator or display may interfere with viewing of the reflectiveelement during normal driving conditions and when the signal indicatormodule is not activated, and may be aesthetically unacceptable. However,if the reflective element is a transflective mirror reflective element,the display area or icon or indicia may be larger than that of anon-transflective mirror reflective element, and may have a sizedimension that is circumscribed by a circle having a diameter of greaterthan about 7 mm or preferably greater than about 15 mm and up to about30 mm or thereabouts. This is because, for transflective mirrorreflector applications, the icon or indicia or display of the signalindicator module is only viewable and discernible by a person viewingthe rearview mirror assembly when it is activated and, thus, when it isdesired or appropriate that the person viewing the mirror assemblyreadily sees and discerns the signal, and is substantially not viewableor discernible during normal driving conditions and when the signalindicator module is deactivated.

Desirably, the signal indicator module (such as for a blind spotindicator) will be sufficiently bright or intense when activated so asto be viewable during high ambient or daytime driving conditions. Forexample, the blind spot indication signal indicator module preferablyhas a luminance of preferably in the range of about 5,000 nits(candelas/square meter) to about 30,000 nits or greater when activatedduring daytime and when viewed via the reflective element from the frontalong its axis of highest brightness/directionality, and with the blindspot signal indictor behind the reflective element and emitting lighttherethrough. The signal indicator module is operable (such as via aphoto sensor control) to have a significantly reduced intensity duringlow ambient lighting, night time driving conditions (and may beautomatically adjusted to the reduced intensity in response to anambient light sensor detecting an ambient light level at or below athreshold light level).

Although shown and described as being located at a driver side exteriormirror, the blind spot/LCA/turn signal indicator of the presentinvention may also or otherwise be located at the passenger sideexterior mirror, if desired. Optionally, a blind spot indicator inaccordance with the present invention may be located at both the driverside mirror assembly and the passenger side mirror assembly of the hostvehicle. The indicator at either side may be selectively activated orilluminated to indicate to the driver of the host vehicle that an objector other vehicle has been detected at that particular side lane regionof the host vehicle. Optionally, the blind spot indicator may beassociated with a blind spot detection and indication system thatincludes one or more indicators at the interior rearview mirror assemblyof the host vehicle. The blind spot indicators may utilize aspects ofthe blind spot indicators and/or blind spot detection systems describedin U.S. Pat. Nos. 6,198,409; 5,929,786 and 5,786,772, and/or PCTApplication No. PCT/US2006/026148, filed Jul. 5, 2006 and published Jan.11, 2007 as International Publication No. WO 2007/005942, which arehereby incorporated herein by reference in their entireties.

Such an indicator or indicators may function as a lane change assist(LCA) indicator or indicators and/or a blind spot indicator orindicators. Such blind spot indicators are typically activated when anobject is detected (via a side object or blind spot detection system orthe like such as described in U.S. Pat. Nos. 7,038,577; 6,882,287;6,198,409; 5,929,786 and 5,786,772, and/or U.S. patent application Ser.No. 11/315,675, filed Dec. 22, 2005, now U.S. Pat. No. 7,720,580; and/orPCT Application No. PCT/US2006/026148, filed Jul. 5, 2006 and publishedJan. 11, 2007 as International Publication No. WO 2007/005942, which arehereby incorporated herein by reference in their entireties) at the sideand/or rear of the vehicle (at the blind spot) and when the turn signalis also activated, so as to provide an alert to the driver of the hostvehicle that there is an object or vehicle in the lane next to the hostvehicle at a time when the driver of the host vehicle intends to moveover into the adjacent lane. Optionally, and alternately, the indicatoror indicators may function as a lane change assist indicator orindicators, where the host vehicle may be detected to be moving into anadjacent lane without the turn signal being activated, and an object orvehicle may be detected at the adjacent lane, whereby the LCA indicatoror indicators may be activated to provide an alert to the driver of thelane change to assist the driver in avoiding unintentional lane changesand/or lane changes when a vehicle or object is detected in the adjacentlane.

A challenge to providing an indicator at the exterior rearview mirrorreflective element is that the back plate and associated components ofthe exterior reflective element subassembly may be exposed to harshenvironmental conditions, such as water spray, rain, dirt and debris andthe like, when the reflective element is mounted at a vehicle. Thus, itis desirable to provide a sealed, water impervious indicator module ordisplay element so as to limit or substantially preclude water ingressor the like into the module or element. Optionally, the back plate andindicator module may be integrally molded to limit water entry into themodule, whereby the illumination source and/or light directing film orthe like may be sealed at the module to protect the electroniccomponents of the module. Optionally, a lens or cover element may beprovided at the planar portion of the back plate and may be sealedthereat to limit water entry into the indicator module through the backplate.

Optionally, and desirably, the display element or signal indicatingmodule may comprise a stand-alone unitary module that is a substantiallysealed, water impervious, indicator module or display module, so as tobe substantially impervious to water ingress or to debris ingress, andpreferably with electrical terminals or connectors (such as a plug orsocket connector) established or incorporated therein or with a lead orwire harness (such as a flying lead or pigtail) established orincorporated therein. The indicator module may be provided as a sealedor substantially sealed unit or module that can be snapped into orotherwise attached or secured (preferably mechanically but optionallyadhesively) at the mirror back plate (and does so substantially orwholly sealingly to limit or substantially preclude water ingress to themodule so that the module and back plate are substantially waterimpervious), preferably at the mirror sub-assembly manufacturingoperation when the mirror reflective element (and any associated heateror other item or element) is joined to the mirror back plate, such as byutilizing aspects of the indicators described in U.S. patent applicationSer. No. 11/520,193, filed Sep. 13, 2006, now U.S. Pat. No. 7,581,859,and/or PCT Application No. PCT/US2006/018567, filed May 16, 2006 andpublished Nov. 23, 2006 as International Publication No. WO 2006/124682,and/or PCT Application No. PCT/US07/82099, filed Oct. 23, 2007 andpublished May 2, 2008 as International Publication No. WO 2008/051910,which are hereby incorporated herein by reference in their entireties.For example, the indicator module may be provided with the illuminationsource and associated elements sealed to the hollow tube or sidewalls ofthe module, and a lens or optic element (such as a transparent lenselement or the like) may be sealed at the opposite end of the hollowtube or housing structure of the module, such that both ends of thehollow tube or housing structure of the module are closed and sealed sothat the module is substantially water impervious as a stand-alonemodule. The sealed signal indicating module, including the light sourceand circuitry, may be supplied or provided to an assembly facility (suchas a mirror assembly facility or the like) from a display elementsupplier, while the back plate may be molded and supplied or provided tothe assembly facility from a back plate supplier. An operator at theassembly facility may attach the display device or indicator moduleand/or circuitry to the back plate (such as to the rear surface of thedisplay receiving portion of the back plate), preferably by snapping thedisplay device or module to snaps or clips or clasps or fingers or thelike molded into the back plate (at its display element receivingportion) to assemble the display or indicator module to the back plate.Optionally, and desirably, the display receiving portion of the backplate and/or the display element (such as at the circuit element orcircuit board) or indicator module may have attaching elements or snapsor clips or prongs (such as cooperating structure molded into the moduleand back plate so that the module is readily attached to or snapped orclasped to the back plate) to ease the assembly and securement of thedisplay element or indicator module to the back plate, such as at or toa display receiving portion of the back plate, so that an operator mayattach the display element or indicator module to the back plate via asnap connection or attachment.

Optionally, and desirably, electrical connection (such as to a powersupply or 12 volt power wire of the vehicle battery/ignition system orto a power feed from a LIN bus controller) to the display circuitry maybe made when the display element is snapped or otherwise attached(preferably mechanically but optionally adhesively) to the back plate,such as by making electrical contact between the display element andmirror circuitry (including circuitry associated with the reflectiveelement and/or mirror assembly, such as electrochromic mirror circuitry,mirror lights and/or display circuitry and the like, typically disposedat a printed circuit board of the mirror assembly) when the displayelement is snapped to the back plate, such as via pressed contact orconnection between respective electrical terminals or contacts of thedisplay element and mirror circuitry as the display element is pressedor snapped or received to the display receiving portion of the backplate, such as by press attaching the display element or module intoreceiving fingers or clips or snaps or the like that are integrallyformed with the display receiving portion of the back plate in theinjection molding operation that manufactures or forms the back plateitself. For example, electrical terminals or contacts may be insertmolded in the display receiving portion so as to be exposed at (orotherwise located at) the rear surface of the display receiving portionfor electrical connection to the display element when the displayelement is attached or snapped to the display receiving portion of theback plate. Alternately, electrical connection to the display device maybe made via other means, such as wires or leads or flying leads or wireharnesses or the like such as pigtails or other suitable connectors orleads, and before or after the display device is snapped or otherwiseattached to the back plate, while remaining within the spirit and scopeof the present invention.

Thus, a method of assembling such a mirror reflective elementsub-assembly may include molding the back plate having an indicatormounting or receiving portion and providing the back plate andreflective element to an assembly facility, while also providing adisplay element or signal indicating module at the assembly facility.Preferably, the display element and the back plate are supplied orprovided to the assembly facility from different sources. An operator atthe assembly facility takes a back plate and a display element and snapsthe display element to the rear surface of the display receiving portionof the back plate to attach and secure the display element at thedisplay receiving portion. The operator also makes the electricalconnection between circuitry or wiring of the mirror assembly orsub-assembly and the display element, either as the display element issnapped to the display receiving portion of the back plate (such as viacontacts at the display element and display receiving portion of theback plate) or at a separate time from the attachment of the displayelement to the back plate (such as via separate connectors or terminalsat or extending from the signal indication module or display element).Optionally, electrical connection to the display element may be madeduring assembly of the reflective element sub-assembly to the mirrorcasing of the mirror assembly (such as via connectors or leads orpigtails extending from the display element).

Thus, the display elements or devices or modules of the presentinvention provide a desired or appropriate iconistic display orindication that, when electrically actuated, emits light that isviewable by a person viewing the mirror reflective element. The displayelement may be formed with the back plate or may attach to the backplate (such as by snapping to the back plate or the like), and providesthe desired angle effect relative to the reflective element. Forexample, the reflective element may be attached to or snapped into theback plate (which includes the display element at a perimeter regionthereof), whereby the display element or module is thus positioned at adesired or appropriate angle relative to the reflective element toprovide the desired or appropriate angle effect for directing the lightfrom the light sources (when electrically actuated) in a desired orpredetermined angle relative to the mirror reflective element. Thus, thedisplay element provides the desired or appropriate preset angle whenthe mirror reflective element is attached to the back plate.

The blind spot indicators of the present invention thus provide adisplay element or indicator that is disposed at or integrally providedwith the back plate. A back plate thus may be provided to a mirrormanufacturer with mounting or attachment structure or receivingstructure for the display element or display circuitry integrally formedwith the back plate. The attachment structure or receiving portion isconfigured to receive or attach to a display element or displaycircuitry or indicator element. A mirror assembler or manufacturer mayattach the display element to the attachment structure or receivingportion of the back plate (such as by snapping display circuitry or acircuit board at the attachment structure), whereby the display elementis oriented at a desired angle relative to the mirror reflective elementwhen attached to the back plate. Thus, illumination emanating from thedisplay element is directed at the desired or appropriate angle forviewing, either by the driver of the host vehicle (for a blind spotdetection system) or a driver of another vehicle (for a turn signalindicator).

The blind spot indicators of the present invention thus are operable toprovide an indication to the driver of the host vehicle that an objector other vehicle has been detected in the lane or area adjacent to theside of the host vehicle. The blind spot indicator may be operable inassociation with a blind spot detection system, which may include animaging sensor or sensors, or an ultrasonic sensor or sensors, or asonar sensor or sensors or the like. For example, the blind spotdetection system may utilize aspects of the blind spot detection and/orimaging systems described in U.S. Pat. Nos. 7,038,577; 6,882,287;6,198,409; 5,929,786 and/or 5,786,772, and/or U.S. patent applicationSer. No. 11/239,980, filed Sep. 30, 2005, now U.S. Pat. No. 7,881,496;and/or Ser. No. 11/315,675, filed Dec. 22, 2005, now U.S. Pat. No.7,720,580, and/or U.S. provisional applications, Ser. No. 60/638,687,filed Dec. 23, 2004; Ser. No. 60/628,709, filed Nov. 17, 2004; Ser. No.60/614,644, filed Sep. 30, 2004; and/or Ser. No. 60/618,686, filed Oct.14, 2004, and/or of the reverse or backup aid systems, such as therearwardly directed vehicle vision systems described in U.S. Pat. Nos.5,550,677; 5,760,962; 5,670,935; 5,877,897; 6,201,642; 6,396,397;6,498,620; 6,717,610 and/or 6,757,109, and/or U.S. patent applicationSer. No. 10/418,486, filed Apr. 18, 2003, now U.S. Pat. No. 7,005,974,and/or of the automatic headlamp controls described in U.S. Pat. Nos.5,796,094 and/or 5,715,093; and/or U.S. patent application Ser. No.11/105,757, filed Apr. 14, 2005, now U.S. Pat. No. 7,526,103; and/orU.S. provisional application Ser. No. 60/607,963, filed Sep. 8, 2004,and/or of the rain sensors described in U.S. Pat. Nos. 6,250,148 and6,341,523, and/or of other imaging systems, such as the types describedin U.S. Pat. Nos. 6,353,392 and 6,313,454, which may utilize variousimaging sensors or imaging array sensors or cameras or the like, such asa CMOS imaging array sensor, a CCD sensor or other sensors or the like,such as the types disclosed in commonly assigned, U.S. Pat. Nos.5,550,677; 5,760,962; 6,097,023 and 5,796,094, and U.S. patentapplication Ser. No. 09/441,341, filed Nov. 16, 1999, now U.S. Pat. No.7,339,149, and/or PCT Application No. PCT/US2003/036177 filed Nov. 14,2003 and published Jun. 3, 2004 as PCT Publication No. WO 2004/047421,with all of the above referenced U.S. patents, patent applications andprovisional applications and PCT applications being commonly assignedand being hereby incorporated herein by reference in their entireties.

Optionally, the indicator or indicators of the present invention mayalert the driver of the host vehicle of other situations or status orthe like. For example, the indicator could function to alert the driverof the host vehicle that the brake lights of the host vehicle arefunctioning properly. Other applications or uses of the indicator may beimplemented, without affecting the scope of the present invention.

The reflective element of the rearview mirror assembly may comprise anelectro-optic or electrochromic reflective element or cell, such as anelectrochromic mirror assembly and electrochromic reflective elementutilizing principles disclosed in commonly assigned U.S. Pat. Nos.6,690,268; 5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,511;5,567,360; 5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673;5,073,012; 5,115,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407 and/or4,712,879, and/or U.S. patent application Ser. No. 10/054,633, filedJan. 22, 2002, now U.S. Pat. No. 7,195,381; Ser. No. 11/021,065, filedDec. 23, 2004, now U.S. Pat. No. 7,255,451; and/or Ser. No. 11/226,628,filed Sep. 14, 2005 and published Mar. 23, 2006 as U.S. Publication No.US-2006-0061008, and/or PCT Application No. PCT/US2006/018567, filed May16, 2006 and published Nov. 23, 2006 as International Publication No. WO2006/124682, and/or U.S. provisional applications, Ser. No. 60/695,149,filed Jun. 29, 2005; Ser. No. 60/690,400, filed Jun. 14, 2005; Ser. No.60/681,250, filed May 16, 2005; and/or Ser. No. 60/692,113, filed Jun.20, 2005, which are all hereby incorporated herein by reference in theirentireties, and/or as disclosed in the following publications: N. R.Lynam, “Electrochromic Automotive Day/Night Mirrors”, SAE TechnicalPaper Series 870636 (1987); N. R. Lynam, “Smart Windows forAutomobiles”, SAE Technical Paper Series 900419 (1990); N. R. Lynam andA. Agrawal, “Automotive Applications of Chromogenic Materials”, LargeArea Chromogenics: Materials and Devices for Transmittance Control, C.M. Lampert and C. G. Granquist, EDS., Optical Engineering Press, Wash.(1990), which are hereby incorporated by reference herein in theirentireties. The thicknesses and materials of the coatings on thesubstrates of the electrochromic reflective element, such as on thethird surface of the reflective element assembly, may be selected toprovide a desired color or tint to the mirror reflective element, suchas a blue colored reflector, such as is known in the art and/or such asdescribed in U.S. Pat. Nos. 5,910,854; 6,420,036 and 7,274,501, and inPCT Application No. PCT/US03/29776, filed Sep. 9, 2003 and publishedApr. 1, 2004 as International Publication No. WO 2004/026633, which areall hereby incorporated herein by reference in their entireties.

Optionally, use of an elemental semiconductor mirror, such as a siliconmetal mirror, such as disclosed in U.S. Pat. Nos. 6,286,965; 6,196,688;5,535,056; 5,751,489 and 6,065,840, and/or in U.S. patent applicationSer. No. 10/993,302, filed Nov. 19, 2004, now U.S. Pat. No. 7,338,177,which are all hereby incorporated herein by reference in theirentireties, can be advantageous because such elemental semiconductormirrors (such as can be formed by depositing a thin film of silicon) canbe greater than 50 percent reflecting in the photopic (SAE J964ameasured), while being also substantially transmitting of light (up to20 percent or even more). Such silicon mirrors also have the advantageof being able to be deposited onto a flat glass substrate and to be bentinto a curved (such as a convex or aspheric) curvature, which is alsoadvantageous since many passenger-side exterior rearview mirrors arebent or curved.

Optionally, the reflective element may include a perimeter metallicband, such as the types described in U.S. Pat. Nos. 7,255,451 and7,274,501, and PCT Application No. PCT/US03/29776, filed Sep. 19, 2003and published Apr. 1, 2004 as International Publication No. WO2004/026633; and/or PCT Application No. PCT/US03/35381, filed Nov. 5,2003 and published May 21, 2004 as International Publication No. WO2004/042457; and/or U.S. patent application Ser. No. 11/226,628, filedSep. 14, 2005 and published Mar. 23, 2006 as U.S. Publication No.US-2006-0061008; and/or U.S. provisional applications, Ser. No.60/692,113, filed Jun. 20, 2005; Ser. No. 60/677,990, filed May 5, 2005;Ser. No. 60/653,787, filed Feb. 17, 2005; Ser. No. 60/642,227, filedJan. 7, 2005; Ser. No. 60/638,250, filed Dec. 21, 2004; Ser. No.60/624,091, filed Nov. 1, 2004, and Ser. No. 60/609,642, filed Sep. 14,2004, which are all hereby incorporated herein by reference in theirentireties. Optionally, the reflective element may include indiciaformed at and viewable at the reflective element, such as by utilizingaspects of the reflective elements described in PCT Application No.PCT/US2006/018567, filed May 15, 2006 and published Nov. 23, 2006 asInternational Publication No. WO 2006/124682; and U.S. provisionalapplications, Ser. No. 60/681,250, filed May 16, 2005; Ser. No.60/690,400, filed Jun. 14, 2005; Ser. No. 60/695,149, filed Jun. 29,2005; Ser. No. 60/730,334, filed Oct. 26, 2005; Ser. No. 60/750,199,filed Dec. 14, 2005; Ser. No. 60/774,449, filed Feb. 17, 2006; and Ser.No. 60/783,496, filed Mar. 18, 2006, which are all hereby incorporatedherein by reference in their entireties.

Optionally, the reflective element may comprise a single substrate witha reflective coating at its rear surface, without affecting the scope ofthe present invention. The mirror assembly thus may comprise a prismaticmirror assembly or planar or non-planar mirror or other mirror having asingle substrate reflective element, such as a mirror assembly utilizingaspects described in U.S. Pat. Nos. 6,318,870; 6,598,980; 5,327,288;4,948,242; 4,826,289; 4,436,371 and 4,435,042; and PCT Application No.PCT/US04/015424, filed May 18, 2004 and published Dec. 2, 2004 asInternational Publication No. WO 2004/103772; and U.S. patentapplication Ser. No. 10/933,842, filed Sep. 3, 2004, now U.S. Pat. No.7,249,860, which are hereby incorporated herein by reference in theirentireties. Optionally, the reflective element may comprise aconventional prismatic or flat reflective element or prism, or maycomprise a prismatic or flat reflective element of the types describedin PCT Application No. PCT/US03/29776, filed Sep. 19, 2003 and publishedApr. 1, 2004 as International Publication No. WO 2004/026633; U.S.patent application Ser. No. 10/709,434, filed May 5, 2004, now U.S. Pat.No. 7,420,756; Ser. No. 10/933,842, filed Sep. 3, 2004, now U.S. Pat.No. 7,249,860; Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat.No. 7,255,451; and/or Ser. No. 10/993,302, filed Nov. 19, 2004, now U.S.Pat. No. 7,338,177, and/or PCT Application No. PCT/US2004/015424, filedMay 18, 2004 and published Dec. 2, 2004 as International Publication No.WO 2004/103772, which are all hereby incorporated herein by reference intheir entireties, without affecting the scope of the present invention.

Optionally, the mirror assembly may include one or more displays, suchas the types disclosed in U.S. Pat. Nos. 5,530,240 and/or 6,329,925,which are hereby incorporated herein by reference in their entireties,and/or display-on-demand or transflective type displays, such as thetypes disclosed in U.S. Pat. Nos. 6,690,268; 5,668,663 and/or 5,724,187,and/or in U.S. patent application Ser. No. 10/054,633, filed Jan. 22,2002, now U.S. Pat. No. 7,195,381; Ser. No. 10/528,269, filed Mar. 17,2005, now U.S. Pat. No. 7,274,501; Ser. No. 10/533,762, filed May 4,2005, now U.S. Pat. No. 7,184,190; Ser. No. 10/538,724, filed Jun. 13,2005 and published Mar. 9, 2006 as U.S. Publication No. US-2006-0050018;Ser. No. 11/284,543, filed Nov. 22, 2005, now U.S. Pat. No. 7,370,983;and/or Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451; and/or PCT Application No. PCT/US03/29776, filed Sep. 9, 2003and published Apr. 1, 2004 as International Publication No. WO2004/026633; and/or PCT Application No. PCT/US03/35381, filed Nov. 5,2003 and published May 21, 2004 as International Publication No. WO2004/042457; and/or U.S. provisional applications, Ser. No. 60/630,061,filed Nov. 22, 2004; Ser. No. 60/667,048, filed Mar. 31, 2005; Ser. No.60/629,926, filed Nov. 22, 2004; Ser. No. 60/531,838, filed Dec. 23,2003; Ser. No. 60/553,842, filed Mar. 17, 2004; and Ser. No. 60/563,342,filed Apr. 19, 2004, and/or PCT Application No. PCT/US03/40611, filedDec. 19, 2003 and published Jul. 15, 2004 as International PublicationNo. WO 2004/058540, which are all hereby incorporated herein byreference in their entireties, or may include or incorporate videodisplays or the like, such as the types described in PCT Application No.PCT/US03/40611, filed Dec. 19, 2003 and published Jul. 15, 2004 asInternational Publication No. WO 2004/058540, and/or U.S. patentapplication Ser. No. 10/538,724, filed Jun. 13, 2005 and published Mar.9, 2006 as U.S. Publication No. US-2006-0050018; and/or Ser. No.11/284,543, filed Nov. 22, 2005, now U.S. Pat. No. 7,370,983; and/orU.S. provisional applications, Ser. No. 60/630,061, filed Nov. 22, 2004;and Ser. No. 60/667,048, filed Mar. 31, 2005, which are herebyincorporated herein by reference in their entireties.

The constructions of the present invention are economical and effectivecompared to the more complicated and potentially more costlyconstructions of other mirror assemblies. The present invention thusobviates the cost and complexity of use of an optics block withcollimating and deviator portions to control direction of light rays, orany equivalent thereof, such as is disclosed in PCT Application No.PCT/US00/07437, filed Mar. 7, 2005 by Gentex Corporation for OPTICS FORCONTROLLING THE DIRECTION OF LIGHT RAYS AND ASSEMBLIES INCORPORATING THEOPTICS, and published Sep. 22, 2005 as International Publication No. WO2005/086777, which is hereby incorporated herein by reference in itsentirety.

Changes and modifications to the specifically described embodiments maybe carried out without departing from the principles of the presentinvention, which is intended to be limited only by the scope of theappended claims as interpreted according to the principles of patentlaw.

1. A method for manufacturing a blind spot indicator module for avehicular exterior rearview mirror assembly, said method comprising:providing a housing, wherein the housing comprises a body portion and afirst connector portion extending from the body portion of the housing,and wherein the body portion is configured to be received at a receivingportion of a backplate of an exterior rearview mirror assembly that isconfigured for attachment to a vehicle; providing a rear cover, whereinthe rear cover comprises a lid portion and a second connector portionextending from the lid portion of the rear cover, and wherein the secondconnector portion extends generally parallel to the lid portion;providing a circuit board having circuitry disposed thereat and havingelectrical terminals extending therefrom; disposing the circuit board atthe housing; attaching the rear cover to a rear end of the housing toencase the circuit board at an inner cavity defined by the housing andthe rear cover, whereby the electrical terminals extending from thecircuit board are disposed between the first connector portion of thehousing and the second connector portion of the rear cover; whereinattaching the rear cover to a rear end of the housing with theelectrical terminals extending from the circuit board disposed betweenthe first connector portion of the housing and the second connectorportion of the rear cover forms an electrical connector configured forconnection to another electrical connector for electrically connectingcircuitry of the circuit board at least to electrical power when theblind spot indicator module is used by an exterior rearview mirrorassembly that is attached to a vehicle; wherein the circuitry includes alight emitting diode that is operable to emit light when electricallypowered; and providing a diffuser element to diffuse light emitted bythe light emitting diode.
 2. The method of claim 1, wherein the bodyportion of the housing comprises structure configured for connecting tostructure of a backplate of an exterior rearview mirror assembly.
 3. Themethod of claim 1, wherein a front end of the body portion of thehousing is configured for adhesive attachment at a rear side of areflective element of an exterior rearview mirror assembly.
 4. Themethod of claim 1, wherein the body portion of the housing is formedfrom a white plastic material and comprises a diffuse reflectivesurface, and wherein the diffuse reflective surface diffusely reflectslight emitted by the light emitting diode.
 5. The method of claim 4,wherein the diffuse reflective surface of the body portion of thehousing comprises a conical-shaped surface that has an opening at afront end of the body portion of the housing.
 6. The method of claim 5,wherein the front end of the body portion of the housing comprises arecess that circumscribes the opening of the conical-shaped surface. 7.The method of claim 6, wherein the step of providing a diffuser elementcomprises receiving the diffuser element at the recess.
 8. The method ofclaim 5, wherein the front end of the body portion of the housing isnon-parallel with the rear end of the housing.
 9. The method of claim 8,wherein the light emitting diode is disposed at the circuit boardoff-center so as to be closer to one sidewall of the body portion of thehousing.
 10. The method of claim 1, wherein the electrical terminals andthe first and second connector portions comprise an electrical socketconnector for electrically connecting circuitry of the circuit board toan electrical plug connector of an exterior rearview mirror assembly.11. The method of claim 1, wherein the circuitry includes a plurality oflight emitting diodes.
 12. The method of claim 1, comprising providingan indicia element at a front end of the body portion of the housingopposite the rear end of the housing at which the rear cover isattached.
 13. The method of claim 12, wherein the indicia elementcomprises a triangular shaped icon.
 14. A method for manufacturing ablind spot indicator module for a vehicular exterior rearview mirrorassembly, said method comprising: providing a housing, wherein thehousing comprises a body portion and a first connector portion extendingfrom the body portion of the housing, and wherein the body portion isconfigured to be received at a receiving portion of a backplate of anexterior rearview mirror assembly that is configured for attachment to avehicle; wherein the body portion of the housing comprises structureconfigured for connecting to structure of a backplate of an exteriorrearview mirror assembly; providing a rear cover, wherein the rear covercomprises a lid portion and a second connector portion extending fromthe lid portion of the rear cover, and wherein the second connectorportion extends generally parallel to the lid portion; providing acircuit board having circuitry disposed thereat and having electricalterminals extending therefrom; disposing the circuit board at thehousing; attaching the rear cover to a rear end of the housing to encasethe circuit board at an inner cavity defined by the housing and the rearcover, whereby the electrical terminals extending from the circuit boardare disposed between the first connector portion of the housing and thesecond connector portion of the rear cover; wherein attaching the rearcover to a rear end of the housing with the electrical terminalsextending from the circuit board disposed between the first connectorportion of the housing and the second connector portion of the rearcover forms an electrical socket connector configured for connection toan electrical plug connector for electrically connecting circuitry ofthe circuit board at least to electrical power when the blind spotindicator module is used by an exterior rearview mirror assembly that isattached to a vehicle; wherein the circuitry includes a light emittingdiode that is operable to emit light when electrically powered; andproviding a diffuser element to diffuse light emitted by the lightemitting diode.
 15. The method of claim 14, wherein the body portion ofthe housing is formed from a white plastic material and comprises adiffuse reflective surface, and wherein the diffuse reflective surfacediffusely reflects light emitted by the light emitting diode.
 16. Themethod of claim 14, wherein the step of providing a diffuser elementcomprises receiving the diffuser element at a recess at a front end ofthe body portion of the housing opposite the rear end of the housing atwhich the rear cover is attached.
 17. The method of claim 16, comprisingproviding an indicia element at the front end of the body portion of thehousing.
 18. A method for manufacturing a blind spot indicator modulefor a vehicular exterior rearview mirror assembly, said methodcomprising: providing a housing, wherein the housing comprises a bodyportion and a first connector portion extending from the body portion ofthe housing, and wherein the body portion is configured to be receivedat a receiving portion of a backplate of an exterior rearview mirrorassembly that is configured for attachment to a vehicle; wherein a frontend of the body portion of the housing is configured for adhesiveattachment at a rear side of a reflective element of an exteriorrearview mirror assembly; providing a rear cover, wherein the rear covercomprises a lid portion and a second connector portion extending fromthe lid portion of the rear cover, and wherein the second connectorportion extends generally parallel to the lid portion; providing acircuit board having circuitry disposed thereat and having electricalterminals extending therefrom; disposing the circuit board at thehousing; attaching the rear cover to a rear end of the housing to encasethe circuit board at an inner cavity defined by the housing and the rearcover, whereby the electrical terminals extending from the circuit boardare disposed between the first connector portion of the housing and thesecond connector portion of the rear cover; wherein attaching the rearcover to a rear end of the housing with the electrical terminalsextending from the circuit board disposed between the first connectorportion of the housing and the second connector portion of the rearcover forms an electrical socket connector configured for connection toan electrical plug connector for electrically connecting circuitry ofthe circuit board at least to electrical power when the blind spotindicator module is used by an exterior rearview mirror assembly that isattached to a vehicle; wherein the circuitry includes a light emittingdiode that is operable to emit light when electrically powered; andproviding a diffuser element to diffuse light emitted by the lightemitting diode.
 19. The method of claim 18, wherein the body portion ofthe housing is formed from a white plastic material and comprises adiffuse reflective surface, and wherein the diffuse reflective surfacediffusely reflects light emitted by the light emitting diode.
 20. Themethod of claim 18, comprising providing an indicia element at a frontend of the body portion of the housing opposite the rear end of thehousing at which the rear cover is attached.